Design And Build A New Cold Press Mini Machine Control By Plc (Programmable Logic Control)

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DESIGN AND BUILD A NEW COLD PRESS MINI MACHINE CONTROL BY PLC (PROGRAMMABLE LOGIC CONTROL)

NOORIZRAQ BIN MOHD Y ASIN

This Report Is Submitted In Partial Fulfillment Of Requirements For The Bachelor Degree of Electronic Engineering (Industrial Electronic)

Fakulti Kejuruteraan Elektronik dan Kejuruteraan Komputer Universiti Tek:nikal Malaysia Melaka

May 2007

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Tajuk Projek Sesi

Pengajian

Say a

UNIVERSTI TEKNIKAL MALAYSIA MELAKA

F AKUL TI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER BORANG PENGESAHAN STATIJS LAPORAN

PROJEK SARJANA MUDA ll

Design and build a new cold press machine control by PLC . . . . 2006/2007 ... .

NOORIZRAO BIN MOHO YASIN

(HURUF BESAR)

mengaku membenarkan Laporan Projek Sarjana Muda ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:

1. Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka.

2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. Sila tandakan ( ...J ) :

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TERHAD"

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TIDAKTEIUIAD

(Mengandungi maidumat yang berdarjah k:eselamatan atau

k:epentingan Malaysia seperti yang tennak:tub di dalam AKT A RAHSIA RASMI 1972)

(Mengandungi maklumat terbad yang telah ditentukan oleh organisasilbadan di mana penyelidikan dijalankan)

Disahkan oleh:

(f ANDATANGAN PENULIS)

Alamat Tetap: ... . LOT 436. JLN lU KAST ARI

81800 ULU TIRAM. JOHOR BHARU

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"I hereby declare that the report is the result of my own, as clearly stated in the sources of references and sources is explained and stated."

Signature: ...

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Name: Noorizraq Bin Mohd Y asin Date: ....

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SUPERVISOR APPROVEMENT

"II we have approve that I've read the Final Year Project report with my opinion this report is fulfill the scope and the quality to be honored with the Ijazah Smjana Muda

KejlU1lteraan Elektronik (Elektronik Industri)."

Signature: •..•...

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Supervisors Name: En Zulhairi Bin Othman

Date: ...

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ZULHAIRI B OTHMAN .

l<~tua Jabalan (Eiektronik lndustrr) Fakulti Kej Elektc<l"W. dan K~i i':JfTl!lUter i>KEKK),

Universiti T9knikal Malays•• Mc:•aka \UreM).

Karung Ber1MlCI 1200.

Ayer Kerch, 75450 Melaka

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I dedicate this to both of my parents, my family, friends and electronic engineering education.

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ACKNOWLEDGEMENT

Firstly, I would like to thankful to Almighty for giving me strength to complete this report. More than that, I would like to thankful to En Zulhairi Bin Othman as my supervisor as long as I have pretend to finish this Final Year Project. He has helped me in many ways such as give an opinion, help to find out the solution and discussion to finish this project.

Moreover,

also

to the

individual

named En. Hj Mohammad Bin Abdullah, this lecturer in Giat MARA Institute, which gives the permission and cooperation to use their workshop and mechanical equipment along the development of this project. His cooperation and help is a lot and I'm thanks for that. Furthermore, to Mrs Bulan Binti

Abdull~ lecturer from UiTM Shah Alam for giving us to use and borrow the pneumatic

equipment likes valve and cylinder.

Not forget to my parent that has gives a supported to make sure this project would be finish smoothly. Also to my project partner Mohd Firdaus bin Hashim for his cooperation and helps along this project. Further, to all my friends have supported me and together estimated the problems in this project. Consequently, I would like to thanks all that have make sure this project is excellent. Hope God bless you are for your kindness. Amen ...

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ABSTRACT

Mini cold press machine is a project to improve previous press machine which

have weakness in safety while operating it. This matter creates a lot of problem and at

the same time the operators and technician have the higher risk to have an accident in

industries.

The solution for this problem is a development of a new program of machine

which running same operation but the machine is more safety and easy to setup when

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VII

ABSTRAK

Project mini cold press machine ini adalah suatu usaha untuk menaik tarafkan

mesin tekan yang sedia ada dimana pada mesin yang sedia ada, bahagian ciri-ciri

keselamatan kurang dititik beratkan. Jadi ia akan mengundang kepada risiko berlakunya

kemalangan ditempat kerja oleh operator dan juruteknik.

Penyelesaian untuk masalah ini ialah membuat program yang baru pada mesin

dimana mesin berfunsi seperti sedia ada teta.pi ia lebih selamat dan senang untuk

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TABLE OF CONTENTS CONTENT PROJECT TITLE DECLARATION DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK

TABLE OF CONTENTS

LIST OF FIGURE

CHAPTER I : INTRODUCTION

1.1 Project overview

1.1.1 Programmable Logic controller

1.1.2 History of Programmable Logic controller

1.1.3 The old way

1.1.4 Disadvantages of the old way

1.1.5 The first programmable controllers

1.2 Objectives of project

1.3 Scope of Project

1.4 Problem Statement

1.5 Project Methodology

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CHAPTER 2 : LITERATURE REVIEW

2.1 Overview ofPC-Based control 14

2.2 Advantages of Computer for industry controller. 16

2.3 PLC Advantages and Disadvantages 17

2.4 Industrial sensor 18

2.5 Electronic Field Sensor 19

2.5.1 Magnetic sensor 20

2.5.1.1 Photoelectric Sensor Construction 21

2.5.1.2 Basic Components 22

2.5.1.3 Photoelectric Sensors of Operation 24

2.5.1.4 DC out Of Photoelectric 24

2.5.1.5 Type of output and load connections 24

2.6 Limit Switch 26

2.7 Actuator (Relay) 27

2.7.1 Relay 27

2. 7 .1.1 Pole and Throw 29

2. 7 .1.2 Application of Relay 30

2.7.1.3 Operation ofRelay 30

2.7.1.4 The Latching Relay Circuit 31

2. 7 .1.5 Advantages of Relays 33

2.7.2 DC Motor 33

CHAPTER

3 :

PROGRAM DEVELOPMENT

3.1 INTRODUCTION 35

3.2 Ladder Logic 38

3.3 Ladder Diagram 38

3.3.1 Ladder Diagram Program for Sorting Device 39

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CHAPTER 4 : INTERFACING AND TROUBLESHOOTING

4.1 Introduction

4.2 Interfacing

4.2.1 Steps to develop the ladder diagram

in

FPWIN GR Programming

4.3 Troubleshooting

4.4 Check Input I Output Device

CHAPTER 5 : RESULT

5.1 Input I Output Assignment

5.2 Wiring Diagram

5.2.1 Wiring Diagram (Inputs)

5.2.2 Wiring Diagram (Inputs- Expansion)

5.3 Wiring Diagram (Outputs)

5.4 Ladder Diagram

5.5 Mnemonic Code

5.6 Cold Press Machine

5.7 Machine Operation (Flow Chart)

CHAPTER 6 : DISCUSSION AND CONCLUSION

6.1 Discussion

6.2 Conclusion

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[image:12.522.26.481.41.817.2]

REFERENCES APPENDIX A APPENDIXB

APPENDIXC

APPENDIXD FIGURES 1.1 1.2 1.3

1.4

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9 2.10 2.11 2.12 3.1 3.2 3.3 3.4 PROGRAM INSTRUCTIONS EXPANSION INSTRUCTION

NETWORK CABLE

INFORMATION SCUD-STATE AUTO SWITCHES

LIST OF FIGURES

TITLE

Example ofPLC ladder diagram.

Flowchart of project methodology

Solenoid valve

DC Motor

Photoelectric Sensor Components

LED (Light Emitting Diode) Construction

Photo Electric Sensor

NPN (Sinking) Field Device Example

PNP (Sourcing) Field Device Example

Roller leaf-low force large movement

Typical Enclosure Actuation

Relays

A relay providing isolation between two circuits

The mechanical operation of relay

The latching relay circuit

DC motor 12 V

A System Approach to Programmable Controller Design

Rung 1 of Ladder Diagram

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3.5 Rung 4 of Ladder Diagram 40

3.25 Rung 24 - Rung 26 of Ladder Diagram 48

3.26 Rung 27 and Rung 28 of Ladder Diagram 48

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3.30 Mnemonic code 50

4.1

Block diagram of the typical component that makes up a PLC

52

4

.

2

Wiring configuration for sorting device with PLC

53

4.3

FPWINGR

54

4.4

Select PLC Type

54

4.5

PLC workspace 55

4.6

PLC work online box 56

4.7

Download to PLC 56

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CHAPTER I

INTRODUCTION

1.1 PROJECT OVERVIEW

lbis machine is use to attach stickers and place button to the radio panel. It is

controlled by PLC. It consist of

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pneumatic cylinder, where each cylinder have their

own function which are to press the radio panel, carry the finished radio panel to the

pickup and place section and there the cylinder is used to grip and pick up the radio

panel.

lbis project is conducted to overcome the problem exist, emergency button not

function if user used machine in manual mode. In automatic mode, user can use just one

hand to handle the machine although have two switch at the machine and time machine

press the panel radio difficult to change at the current machine by enhancing the

machine, modify the program and added external timer. lbis is to produce a mini

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1.1.1 PROGRAMMABLE LOGIC CONTROL (PLC)

Automation of many different processes, such as controlling machines or factory

assembly lines, is done through the use of small computers called a programmable logic

controller (PLC). This is actually a control device that consists of a programmable

microprocessor, and is programmed using a specialized computer language. Before, a

programmable logic controller would have been programmed in ladder logic, which is

similar to a schematic of relay logic. A modem programmable logic controller is usually

programmed in any one of several languages, ranging from ladder logic to Basic or C.

Typically, the program is written in a development environment on a personal computer

(PC), and then is downloaded onto the programmable logic controller directly through a

cable connection. The program is stored in the programmable logic controller in

non-volatile memory.

Programmable logic controllers contain a variable number of Input/Output (1/0)

ports, and are typically Reduced Instruction Set Computer (RISC) based. They are

designed for real-time use, and often must withstand harsh environments on the shop

floor. The programmable logic controller circuitry monitors the status of multiple sensor

inputs, which control output actuators, which may be things like motor starters, solenoids, lights and displays, or valves.

The programmable logic controller has made a significant contribution to factory

automation. Earlier automation systems

had

to use thousands of individual relays and

cam timers, but all of the relays and timers within a factory system can often be replaced

with a single programmable logic controller. Today, programmable logic controllers

deliver a wide range of functionality, including basic relay control, motion control,

process control, and complex networking, as well as being used in Distributed Control

Systems.

Digital signals yield an on or off signal, which the programmable logic controller

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controls. and these analog signals are seen by the programmable logic controller as

floating point values.

There are several different types of interfaces that are used when people need to

interact with the programmable logic controller to configure it or work with it. This may

take the form of simple lights or switches or text displays, or for more complex systems,

a computer of Web interface on a computer running a Supervisory Control and Data

Acquisition (SCADA) system. [I]

Programmable logic control or PLC is the most commonly used industrial

automation technique in the world. It is universally applied for factory automation.

process control and manufacturing systems.

Programmable logic control originated from the creation of computerized

versions of relay control systems used to control manufacturing and chemical process

systems. The programming is done using a special technique called ladder logic, which

allows sequences of logical actions to be set up, inter-linked and timed. A standard task

in logic control is batch control and sequencing in a process system.

A PLC or Programmable Logic Controller is a user friendly, microprocessor

specialized computer that carries out control functions of many types and levels of

complexity. Its purpose is to monitor crucial process parameters and adjust process

operations accordingly. It can be programmed, controlled and operated by a person

unskilled in operating computers. Essentially, a PLC's operator draws the lines and

devices of ladder diagrams with a keyboard onto a display screen. The resulting drawing

is converted into computer machine language and run as a user program.

PLC will operate any system that bas output devices that go on and off (Discrete,

or Digital, outputs).lt can also operate any system with variable (analog) outputs. The

Programmable Logic Control can be operated on the input side by ON/OFF devices or

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1.1.2 IDSTORY OF PROGRAMMABLE LOGIC CONTROL (PLC)

The programmable logic controller may be the best example ever of taking an

existing technology and applying it to meet a need. In the 1960s and 1970s, industry was

beginning to see the need for automation. Industry saw the need to improve quality and

increase productivity. Flexibility had also become a major concern. Industry needed to

be able to change processes quickly to meet the needs of the consumer.

Programmable logic controllers were first created to serve the automobile

industry, and the first programmable logic controller project was developed in 1968 for

General Motors to replace hard-wired relay systems with an electronic controller.

1.1.3 THE OLD WAY

Imagine an automated manufacturing line in the 1960s and 1970s. There was

always a huge wiring panel to control the system. The wiring panel could cover an entire

wall. Inside the panel were masses of electromechanical relays. These relays were all

hardwired together to make the system work. Hardwiring means that an electrician had

to install wires between the connections of the relays. An engineer would design the

logic of the system and the electricians would be given a blueprint of the logic and

would have to wire the components together. There were hundreds of electromechanical

relays in a system before programmable logic controllers were developed.

The drawing that the electrician was given was called a ladder diagram. They

were called ladders because they resemble a ladder in appearance. The ladder showed all

the switches, sensors, motor, valve, relays, etc, that would be in the system. It was the

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5

Rl4 X26 Rl8 Rl5

1 , K 30

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Rls~'l

. _ _ l _______

____..rT!X

Tl Rl5 X25 X28 R20

R16~ ~

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-Figure 1.1: Example ofPLC ladder diagram.

Note the similarity in appearance to a ladder. There are three rung in this

example. Power is represented by the left and right upright. There are five inputs and

two outputs in the example. Inputs are on the left, output at the right of each rung.

It is not hard to imagine that the engineer made a few small errors in his/her

design. It is also conceivable that the electrician may have made a few errors in wiring

the system. It is also not hard to imagine a few bad components. The only way to see if

everything was correct was to run the system. Systems are normally not perfect on the

first attempt.

Troubleshooting was done by running the actual system. This was a very

consuming process. The system had to be disabled for wiring changes. This means that

all of the production personnel associated with that production line was without work

until the system was repaired. After the electrician had completed the troubleshooting

[image:19.522.48.480.93.624.2]

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1.1.4 DISADVANTAGES OF THE CONVENTIONAL WAY

One of the problems with this type of control is that it is based on mechanical relays. Mechanical devices are usually the weakest link in systems. Mechanical devices have moving part that can wear out If one relay failed, the electrician might have to troubleshoot the whole system again. The system was down again until the problem was found and corrected.

Another problem with hardwired logic is that if a change must be made, the system must be shut down and the panel rewired. If a company decided to change the sequence of operations (even a minor change), it will be a major expense and loss of productions time while the system do not produce parts.

1.1.5 THE FIRST PROGRAMMABLE CONTROLLERS

General Motor saw the need for a replacement for hardwired control panels. Increased competition forced the automak.ers to improve manufacturing performance in

both quality and productivity. Flexibility, rapid changeover and reduced downtime

became very important.

GM realized that a computer could be used for logic instead of hardwired relays.

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1.2 OBJECTIVES

The objective of this project is to identify the all of function the cold press

machine and the input/output equipment like sensor, switch, external timer and solenoid

valve.

Another objective is to study the component of Flexible Manufacturing System

(FMS) to conform to the model to be developed. The component of Flexible

Manufacturing System is pneumatic equipment (solenoid valve and pneumatic cylinder)

and control equipment (Programmable Logic Control). PLC is the most commonly used

industrial automation technique in the world. It is universally applied for factory

automation, process control and manufacturing systems.

To build a new Flexible Manufacturing System (FMS) model that will be cost,

time and quantity effectiveness is other objectives should be done. Machine need one

worker only to handling machine and send the set, not two workers like other machine.

In this case, we can cut cost for pay one worker. The last objective is for build low cost

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1.2 SCOPE OF WORKS

The scopes of the project are:

1. Identify function of the electronics component like sensor and switch for control/handle pneumatic system.

2. Identify how to use console Programmable Logic Control for key in program from ladder diagram to PLC (Programmable Logic Control).

3. Identify detail function of machine and how PLC (Programmable Logic Control) control machine.

1.3 PROBLEM STATEMENT

1. Machine not safe to used, in manual mode and also in automatic mode. In manual mode, worker not safe to use the machine because machine can't stop immediately while doing maintenance job. In automatic mode, user can use just one hand to handle the machine although have two switches at the machine. The programming will be change to make sure machine are safe to use in manual mode or automatic mode.

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3. Time for machine to press the panel radio is difficult to change and need a long

time to check and modify the program. So that's why we need the external timer.

If timer of press the panel radio wants to change, we just adjust at the external

timer. In this case, machine is easy to use and if maintenance wants to change time of machine press the panel radio, it is not a waste the time ..

1.4 PROJECT METHODOLOGY

Find idea to done the project

Research

ana

identifY

problem oo mac'!n.n.e

Mate <iac'llsmn wih

~or to make

pcopotal and ge11U po' of \!lew

D.ist1.1SS1on Wlih ~oup

member to get W6:'J to

ovet"COme ihe pcoblem

Find Pl'ogr.acl l<>

conlrol the machine

Wiring the PLC

Iruert prowam iJrto the'PLC

Tcst:n& l$ oonc

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t<> project

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1bis project was carried out in two main phases, which were the fabrication of

model and interfacing the model with Programmable Logic Controller. The idea to

proposed and done this project comes from the experiences that have got during

industrial training program. While working as technician at production engmeer

department there are many problem had occurred at the assembly line.

Some of the problem that can be seen is at the press machine, puncture test

machine, and AMIFM machine. Press machine had been chosen because it not uses

external equipment that exists on the puncture test machine and AMIFM machine. In

addition it didn't need high voltage like puncture test that need 11 KV so that product

can be test There are seveml problems that can be found at the

machine:-1. Machine can't stop immediately in auto mode, in automatic mode; user can only

use one hand to operate the machine although there are two switches at the machine

2. Time for machine to press the panel radio is difficult to change and need a long

time to check and modify the program.

Discussion is making with supervisor about title that going to be proposed,

problem at the machine, equipment that going to be used and make proposal from its

point of view.

Discussion also been made with group member to overcome the problem; discuss

how added function of machine because I have to program the controller of the cold

press machine to achieve the objective.

Find suitable program to control the machine is finds and PLC had been chosen

to control the machine. The main factor of using PLC because of the experience that

been getting during industrial training. Nais had been choose because this PLC that been